Blow molded pallet with wave-like supports

ABSTRACT

A pallet system has a pallet body that includes a first portion with an outer surface and an inner surface that has at least a portion distant from the outer surface and a corrugating form. The pallet body also includes a second portion with an outer surface and an inner surface that has at least a portion distant from the outer surface and a corrugating form. The inner surface of the first portion is connected to the inner surface of the second portion between each respective corrugating form. Channels and protrusions may also be used to add strength and support to the body. The portions are connected at tack off points.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates in general to the field ofplastics. More particularly, the present invention relates to a palletsystem and a pallet apparatus and a method of pallet manufacturing.Specifically, one preferred embodiment of the present invention relatesto blow molding a first pallet section or portion with a wave-likesupport and then inserting it into another mold to join it to a secondblow molded pallet section or portion with a wave-like support.

[0003] 2. Discussion of the Related Art

[0004] Pallets are used for transporting and storing various types ofcargo throughout the world. Therefore, it is important for a pallet tobe lightweight, compact and strong. Traditionally pallets were made ofwood, however, plastic pallets are now being used with increasedfrequency as they are lightweight, generally stronger, do not absorbmoisture, and they can be cleaned and disinfected which is important inparticular for the food industry. One disadvantage of plastic pallets isthat they tend to break up with continued use over time. Therefore, forthese and other various reasons it is important that plastic pallets bereinforced by a variety of means.

[0005] The below-referenced U.S. patents disclose embodiments that wereat least in part satisfactory for the purposes for which they wereintended. The disclosures of all the below-referenced prior UnitedStates patents, in their entireties, are hereby expressly incorporatedby reference into the present application for purposes including, butnot limited to, indicating the background of the present invention andillustrating the state of the art.

[0006] U.S. Pat. No. 5,417,167 discloses a plastic shipping pallet ofthe type usually manufactured from wood which is made of hollow plasticstringers and deck boards. The stringers and deck boards are made ofplastic materials that may be either virgin plastic, recycled plasticsor mixes. The stringers and deck boards are hollow but have closed endsto prevent entry of dirt, fluids, insects and vermin. The stringers anddeck boards may be made in a blow molding process or using continuousextrusion and molding processes similar to that used in the manufactureof corrugated pipe. Various connection configurations for affixing thedeck boards to the stringers are described including fixation by screwsas well as interlocking connections between the plastic parts themselvesand the use of separate interlocking components which engage the deckboard and stringers.

[0007] U.S. Pat. No. 5,845,588 discloses a pallet fabricated of athermoplastic material which is produced by joining togetherindividually fabricated structural components, each of which isindividually thermoformed from an extruded plastic parison of amultilayer structure. The structural components include a deck in theform of a continuous sheet with longitudinal and transverse sides, oneor more upper runner components fastened by their top side to the bottomof the deck, each of which includes a cross member with downward-facingposts, and one or more lower runner components, each of which includes across member with upward-facing posts and which is fastened by the topsof its posts to the bottoms of matching posts on the corresponding upperrunner components.

[0008] U.S. Pat. No. 5,868,080 discloses a reinforced plastic palletconstruction and assembly method are presented wherein multiplereinforcing bars are employed. At least some of the reinforcing barshave an exposed surface at a topside surface, underneath surface orunderside surface of the pallet. In addition to functioning as areinforcing member, the exposed surfaces of the reinforcing barscomprise an anti-skid surface for maintaining positioning of payload onthe pallet or facilitating transport of the pallet, e.g., via a forkliftor automated transport system. Various techniques for retaining thereinforcing bars within channels formed in the plastic pallet body aredescribed. The reinforcing bars preferably comprise composite structuralmembers of fiberglass-reinforced plastic fabricated from a pultrusionprocess.

[0009] U.S. Pat. No. 6,209,464 discloses a pallet that includes arectangular support deck having a substantially planar upper supportingsurface including a plurality of channels formed therein and extendingacross the pallet. The deck includes support members extending from anunderside of the deck that nest in recesses formed in the upper surfaceof the deck. An alignment portion is formed at a center point along thefirst edge of the deck and a second alignment portion is formed at acenter point of an opposed edge of the deck. The alignment portionincludes angled sides for receiving a tapered member of a complementarydevice.

SUMMARY AND OBJECTS OF THE INVENTION

[0010] It is one object of the present invention to provide a palletsystem that is relatively inexpensive to manufacture, recyclable, andenvironmentally friendly.

[0011] It is another object, to provide a pallet design that isstructurally strong, yet relatively lightweight, and generally easy tomanufacture.

[0012] In accordance with one aspect of the invention, the inventivepallet system has a first portion and a second portion having interiorsthat fit together to provide strength and stability to a preferably blowmolded pallet body.

[0013] These and other aspects and objects of the present invention willbe better appreciated and understood when considered in conjunction withthe following description and the accompanying drawings. It should beunderstood, however, that the following description, while indicatingpreferred embodiments of the present invention, is given by way ofillustration and not of limitation. Many changes and modifications maybe made within the scope of the present invention without departing fromthe spirit thereof, and the invention includes all such modifications.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] A clear conception of the advantages and features constitutingthe present invention, and of the construction and operation of typicalmechanisms provided with the present invention, will become more readilyapparent by referring to the exemplary, and therefore non-limiting,embodiments illustrated in the drawings accompanying and forming a partof this specification, wherein like reference numerals designate thesame elements in the several views, and in which:

[0015]FIG. 1 shows a top perspective view of one embodiment of thepallet of the present invention;

[0016]FIG. 1A shows a cross-sectional view along line A-A in FIG. 1;

[0017]FIG. 1B shows a cross-sectional view along line B-B of FIG. 1;

[0018]FIG. 1C shows a cross-sectional view along line C-C of FIG. 1;

[0019]FIG. 1D shows a cross-sectional view along line D-D of FIG. 1;

[0020]FIG. 1E shows a cross-sectional view along line E-E of FIG. 1;

[0021]FIG. 2 shows a bottom-perspective view of the pallet of FIG. 1;

[0022]FIG. 3 shows an exploded top-perspective view of the pallet ofFIG. 1;

[0023]FIG. 4 shows an exploded bottom-perspective view of the pallet ofFIG. 1;

[0024]FIG. 5 shows an exploded front view of the pallet of FIG. 1;

[0025]FIG. 6 shows mold form halves used to form the pallet of FIG. 1;

[0026]FIG. 7 is a top-perspective view of another embodiment of thepresent invention;

[0027]FIG. 8 is a bottom-perspective view of the pallet of FIG. 7;

[0028]FIG. 9 is a front view of the pallet of FIG. 7;

[0029]FIG. 10 is a side view of the pallet of FIG. 7;

[0030]FIG. 11 is an exploded top-perspective view of the pallet of FIG.7;

[0031]FIG. 12 is an exploded bottom perspective view of the pallet ofFIG. 7;

[0032]FIG. 13 is an exploded top-perspective view of yet still anotherembodiment of the pallet of the present invention;

[0033]FIG. 14 is an exploded bottom-perspective view of the pallet ofFIG. 13;

[0034]FIG. 15 is an exploded front view of the pallet of FIG. 13;

[0035]FIG. 16 is a side view of the pallet of FIG. 13; and

[0036]FIG. 17 is an exploded top-perspective view of yet still anotherembodiment of the pallet of the present invention;

[0037]FIG. 18 is an exploded bottom-perspective view of the pallet ofFIG. 17;

[0038]FIG. 19 is sectional schematic with a magnified view of the palletof FIG. 17;

[0039]FIG. 20 is a side view of another embodiment of the presentinvention; and

[0040]FIG. 21 is an a schematic illustrating the method of the presentinvention.

[0041] In describing the preferred embodiment of the invention, which isillustrated in the drawings, specific terminology will be resorted tofor the sake of clarity. However, it is not intended that the inventionbe limited to the specific terms so selected and it is to be understoodthat each specific term includes all technical equivalents which operatein a similar manner to accomplish a similar purpose. For example, theword “connected” or terms similar thereto are often used. They are notlimited to direct connection but include connection through otherelements where such connection is recognized as being equivalent bythose skilled in the art.

DETAILED DESCRIPTION

[0042] The present invention and the various features and advantageousdetails thereof are explained more fully with reference to thenon-limiting embodiments described in detail in the followingdescription.

1. Resume

[0043] As shown in the embodiment of FIG. 1, the present inventioncomprises a pallet system that has a body including a first portion anda second portion. The first portion is preferably the top portion andthe second portion is preferably the bottom portion. The first portionhas a generally planar outer surface and an inner surface at least aportion of which is distant the outer surface. The inner surface of thefirst portion is non-planar. In one preferred embodiment adjacent oneset of outer edges, the inner surface has a pair of generally U-shapedfeet that extend from one edge of the pallet to an opposing edge.Preferably, at the bottom of each foot is a rib that extends the lengthof the foot. Inside each foot and parallel to it is a channel. Betweenthe channels and parallel to them is a middle support having generallythe same width as each channel. The middle support extends away from theouter surface a distance less than the distance that the feet extendaway from the outer surface.

[0044] The channels and middle support has a succession of curves havingspaced apart ridges that define grooves.

[0045] The second portion has an outer surface and an inner surface atleast a portion of which is distant the outer surface. The innersurfaces of the first and second portions each have complementaryundulating forms. The inner surfaces of the first and second portionseach include a succession of curves.

[0046] The outer surface of the second portion includes at least a pairof channels that extend from one edge to an opposing edge. The pair ofchannels is dimensioned and configured to receive tines of a forklift.On each outer side of the tine-accepting channels is a leg with at leastone foot that extends parallel to the channels from one edge to anopposing edge and that rests on a surface. In a preferred embodiment,the feet run the longitudinal length of the pallet. In between the pairof channels is a support that extends parallel to the channels andpreferably spans longitudinal length of the pallet.

[0047] The inner surfaces of the first and second portions each includesa succession of curves having rises and falls that run perpendicular tothe series of ridges and grooves on the outer surface of the secondportion.

[0048] The inner surface of the first portion is molded to the innersurface of the second portion.

[0049] The outer surface of the second portion comprises a series ofridges and grooves.

[0050] The outer surface of the first portion is generally planar suchthat, e.g., boxes can be stacked upon it.

[0051] The inner surface of the first portion is connected to the innersurface of the second portion. The inner surface of the first portionand the inner surface of the second portion comprise complementarilyshaped surfaces.

2. PREFERRED EMBODIMENTS

[0052] With reference now to the drawing figures in which like referencenumerals designate like parts throughout the disclosure, FIG. 1 shows apallet system 5 of the present invention. As best shown in FIGS. 1A-FIG.4, the pallet system 5 consists of a pallet body 10 having a first orupper portion 12 with a first outer surface 14 and a first inner surface16 (see FIG. 4). The pallet body also has a second or bottom portion 20having a second outer surface 22 and a second inner surface 24 (see,e.g., FIGS. 2 and 3). A first distant portion 18 is also contained inthe first portion 12 and a second distant portion 26 is contained in thesecond portion 20 (see FIG. 1A). The first portion 12 preferably has afirst set of protrusions 30 which connect to the second portion 20. Inone preferred embodiment, protrusions 30 interdigitate between a secondset of protrusions 32 located on the second portion 20 (see FIG. 3).

[0053] As best shown in FIG. 4, a first leg 38 and a second leg 39 mayalso be provided on the pallet body 10. In other embodiments, these legsactually may be made up of one or more feet (40, 41, 42, 43, 44, and 45)as shown in FIGS. 7 through 12. As shown in yet another embodiment(FIGS. 13-15), the legs 38, 39 are preferably formed from an extension51 on the first portion 12 which is received by a channel 46 on thesecond portion 20 as best shown in FIG. 15.

[0054] In one embodiment, one significant feature is that a plurality ofcorrugations 56 a, 58 a from the first portion 12 preferablyinterconnect with a plurality of corrugations 56 b, 58 b from the secondportion 20. The corrugations may be made up of a combination of bothhumps 56 and valleys 58 in combination with ridges 52 and grooves 48(see, e.g., FIGS. 4, 12 and 14). The ridges, humps, valleys and groovesmay have various shapes and sizes. When the corrugations are matedtogether, the upper corrugations 56 a, 58 a may have extending members76 in the middle between the tine holes which fit into cavities 78 inthe tine holes on the lower corrugations 56 b, 58 b (see FIG. 14).

[0055] The corrugations may run along the X direction and/or the Ydirection. Preferably, the Y direction is 48 inches and the X directionis 40 inches.

[0056] As shown in FIG. 15, one preferred embodiment also has apertures80 which receive ribs or locking members 82. Escape holes 84 may also beformed in the first portion 12 and the second portion 20 by mold formpins (not shown) to allow the injected gases which are inserted in theblow molding process to properly escape. When the extending members 76and the cavity 78 come together while the blow molded plastic portionsare still hot, they may form a tack-off point 90 (see FIGS. 1, 7, 9).

[0057] As shown in FIG. 13, the embodiment may have inserts 94 which areformed from a more rubberized plastic (e.g., EVA). This material alsohas greater friction to prevent loads from slipping off an otherwiseslick polyethylene top surface. Alternatively, a coating 96 may beapplied as shown in FIG. 11 where it is shown applied to one half of thefirst outer surface 14.

[0058] In one embodiment, best shown in FIG. 16, the body 10 of thepallet system is “bowed” at an angle α from the horizontal plane. Angleα is preferably 6° of less.

[0059] 2. Manufacture

[0060] The preferred embodiment is preferably manufactured in severalways.

[0061]FIG. 17 shows a general process flow diagram illustrating themethod used to construct the pallet of the present invention. Theprocess begins preferably with the first forming of the bottom portionin a conventional blow molding form having two halves. The cycle timesand molding characteristics are adjusted to the materials being molded.When inserts are required they may be molded in a separate injectionmolding process. The bottom portion is formed to mate with the mold formused to blow mold the top portion. Additional chemical bonding orbond-promoting agents may be used or some roughening of the surface mayalso be used to enhance bonding. A gap or air port may be providedbetween these pieces so that air can be released during the bonding ofthe two portions together. Such a gap normally occurs around the midlineor pinch-off area where the mold halves meet.

[0062]FIG. 6 depicts one pair of symmetrical extrusion mold forms whichare used to form a pallet portion. Water-cooling channels within themold form (not shown), parison pinch-offs (not shown) and air/gas accessports or needles (not shown) are provided in conventional fashion withinthe mold form to effect proper molding. It may be necessary to providegrooves, clamps, or other retaining mechanisms within the mold toprovide retention of the lower piece into the mold form for the upperpiece.

[0063] First, various types of plastic (e.g., virgin and recycle) areadded to a hopper. The hopper feeds an extruder where the plastic isheated. Parison of molten plastic (e.g., a polyethylene material) isnext extruded and vertically suspended between mold halves. Typically,the material is heated to a molten state and the temperature is in arange from 350° to 450° F. Once the material is introduced into the moldform, the parison is pinched off as the mold closes. After the moldclosed about the parison and an air or gas is injected via one or moreinjection needles into the parison, the air is directed such that thematerial is blown onto the contoured wall surfaces of the mold forms.

[0064] The pallet portions may be made out of a variety of materialssuch as linear low polyethylene (LLPE), high-density polyethylene(HDPE), and/or may include some natural rubber. For example, a mixtureof 20% to 30% polyethylene and a natural rubber product called Duraprenemay be used. This allows for a flexible yet strong pallet which canproperly carry up to three thousand pounds. One preferred material willmeet the following ASTM standards: D297, D412, Die C, D624, Die C, F36,D2240, F147, D471, as well as ASTM #1, #3, and Fuel A and Fuel C.Duraprene can be obtained through a company called Lamatek (seehttp://www.lamatek.com).

[0065] Next, the bottom portion is placed into a mold form to make anupper portion. Retaining pins or clamps may hold the bottom portion inthe mold form. Parison is again extruded between the mold form halvesand the above process begins again. The blown polyethylene materialthereby retains the bottom portion against the mold walls. During thisinsert molding process, other already formed pieces (such as rings toadd surface friction) may also be inserted into the blow mold form(having two halves) where they are retained during the blow-moldingprocess and integrally bonded into one of the newly formed blow-moldedsurfaces. Relative temperatures of the inserted pieces and/or bottomportion and the material are such that the hot material coats and meltsthe inner surface of the pieces and/or the portion to coalesce and formintegral bond with one another. Depending on the materials, the moldforms may also preheat and soften the pieces and/or portions. For thepieces, an EEA material may be used while polyethylene may be used forthe portions.

[0066] The EEA material used has a melt temperature typically in therange of 250° to 300° F. and the preferred polyethylene materialtypically has a melt temperature in the range of 375° to 450° F. Otherrelative temperature ranges could be used, provided the materials willflow melt bond to one another. It is important that the dwell time ofeach mold piece is properly set to prevent the formation of air pocketsat the bonding surface which can prevent proper lamination.

[0067] Further increasing the cooling time may be necessary to preventany sinking or shrinking of the bonding surface. Again, which couldproduce unwanted delamination. Alternatively, reducing the dwell timehelps to release air which becomes trapped at the bonding surface duringmolding. Typical cycle times of 1x to 2x at air gas pressures of 80 to150 psi and dwell times of 1y to 1.5y, where y and x are comparablevalues for noncomposite pieces of identical design.

[0068] While the pallet body 10 is preferably formed from two blowmolded portions, it is possible the portions may be formed by injectionmolding, thermo-forming, or another plastic molding process.

[0069] The depths of any grooves or projections (e.g., FIG. 15references 80, 82) which are used to enhance bonding can be adjusted totake into account shrinking and/or melting that occurs at the bonding ofthe surface. The projections may comprise annular or lateral ribs orstuds or combinations thereof. Dovetail projections or studs with headsmay also be used. Some projections may serve to retain a tread piecewhile others create an air channel and melt away.

[0070] As shown in FIGS. 13-16, the upper portion 12 may be made of afirst plastic mixture and the bottom portion 20 may be made of a secondplastic mixture. Such mixtures may give the give the portion differentanti-slippage or weight-bearing properties. For example, the upperportion material (e.g., EEA and real rubber) may be stiffer while thebottom portion material may have greater impact strength.

[0071] The pre-formed insert pieces 94 are preferably constructed from alow density, relatively soft polyethylene material of the polyolefinfamily. The material particularly comprises an ethylene-ethyl acrylate(EEA). This material doesn't readily bond to polyethylene usingtraditional adhesion methods, such as RF sealing, ultrasonic bonding orspin welding. EEA, however, is commercially available in a number ofcompositions which accommodate a variety of operating temperatures ormelt ranges below that of the materials used to blow mold the pallet 5.Two 18% EEA compositions having respective 20 and 6 melt ranges havebeen shown to be desirable. The lower temperature (i.e. 20 melt)material is softer and more readily assures proper bonding, but is lessscuff resistant.

[0072] Alternative pre-formed insert materials may comprise ethyl-vinylacetate (EVA), low-density polyethylene (LDPE) or linear, low-densitypolyethylene (LLDPE). Variations of the foregoing materials may also beblended, as necessary, to provide desirable mechanical properties for aparticular application.

[0073] An EEA pre-formed insert material is presently preferred for thepallet 5 because it is relatively durable and readily bonds under flowmelt conditions to the polyethylene upper portion. The EEA material isalso less dense than many materials, in particular, the polyethylenematerials used to typically mold the pallet. The pre-formed insert 94thus exhibits a softer texture than the pallet top portion 12, whichproduces improved traction between the pallet and the load. Dependingupon the application, it may however be desirable to use a harderpre-formed insert material, similar to that of the pallet top portion12.

[0074] In the embodiments shown in FIGS. 17-20, pallet 99 has a body100. The runners 101 attached to the body 100 that are preferablydesigned with a slight radius 102, 103 on the outside edges 104, 105 toadd strength and durability and to prevent the pallet 99 from gettinghung up on expansion joints in a warehouse floor or a conveyor and alsoto prevent breakage of fragile corners or edges. In this embodiment, allof the pallet body's edges (e.g., 125) have radiused corners (see e.g,106, 108, 110, 112, 114, and 116).

[0075] This pallet 99 may also have three components 118, 120, and 122(a top, middle and bottom section respectively as shown in FIGS. 17-19)or two components (e.g., a top and bottom section as shown in FIG. 20)depending on the application. For example, the three-portion palletwould be used for more heavy-duty applications while the two-portionpallet may be used for medium-duty applications. The same molds may beused to make the top sections and bottom sections of the three portionand two portion pallets. However, as can be seen, a middle section moldis only likely to be used by the three-portion heavy-duty pallet.

[0076] When the portions are insert molded, the portion weld points ortack or kiss-offs 126 are preferably found at both the peaks 130 and thevalleys 132 of the inner surfaces 140, 141, 142, 143 where the portions118, 120, and 122 meet as shown in FIG. 18. This feature gives addedstructural strength and stability to the pallet 99. FIG. 19 illustratesthat this embodiment of the blow-molded pallet 99 has a 0.5 inch lip 150around the center edge 160. The lip 150 allows for easier handling bypallet transfer equipment and provides an anchor point for plasticshrink-wrap and/or tie down straps.

[0077] In the preferred embodiment shown in FIGS. 17-19, the runners arepreferably about 4.75 inches high and about 6.5 inches wide. The peaksextend to a height of about 0.75 inches from the inner surface and areabout 1 inch wide. The pallet from top surface to bottom surface isapproximately 5.75 inches high. The length of the pallet may 40 inchesand the width may be 48 inches.

[0078] The runners or legs 101 are preferably formulated from a punctureresistant HDPE plastic resin. These HDPE plastics may be acquired fromFORMOSA PLASTICS CORPORATION USA (see www.fpcusa.com) and may, forexample, include hexane copolymers, homopolymers, extra high molecularweight copolymers having densities between about 0.945-0.955 g/cc andmelt indexes about 0.30-10.0(HLMI) g/10 min. Alternatively, punctureresistant properties may be added by blending in plastics with thesecharacteristics into the typical polyethylene material. Punctureresistance of the plastic is desirable in some applications because somepallets are frequently moved by forklifts bearing sharp tines or forks.

[0079] Of course, one of ordinary skilled may see other possible changesto the pallet designs for example with the corrugations running in the40-inch direction. In the some of the above described embodiments, thecorrugations in the bottom portion of the pallet stop at the inside faceof the runners, with the top surface (of the bottom portion) droppinginto the runners. However, another design change (see, e.g., FIGS.17-19) involves running the corrugations to the outside of the runners,except at each end of the runners where the top surface will continue todrop into the runner. This change will help to stiffen the runners(rotationally), but still provide an extra layer at the ends of therunners that see impact from forks.

[0080] Adding additional structural rigidity may be accomplished byadding an aluminum or steel insert, running the length of the runners,in, for example, the four-way pallet design.

[0081] The individual components described herein need not necessarilybe formed in the disclosed shapes, or assembled in the disclosedconfiguration, but could be provided in virtually any shape, andassembled in virtually any configuration. Furthermore, all the disclosedfeatures of each disclosed embodiment can be combined with, orsubstituted for, the disclosed features of every other disclosedembodiment except where such features are mutually exclusive. Finally,it is intended that the appended claims cover all such additions,modifications and rearrangements. Expedient embodiments of the presentinvention are differentiated by the appended subclaims.

What is claimed is:
 1. A pallet comprising: a first portion having anouter surface and an inner surface at least a portion of which isdistant the outer surface; and a second portion having an outer surfaceand an inner surface at least a portion of which is distant the outersurface, wherein the inner surface of the first portion indigitates withthe inner surface of the second portion.
 2. The pallet of claim 1wherein the inner surface of the first portion and the inner surface ofthe second portion comprise complementarily shaped surfaces.
 3. Thepallet of claim 1 wherein the inner surfaces of the first and secondportions each have an undulating form.
 4. The pallet of claim 1 whereininner surfaces of the first and second portions each comprise asuccession of curved protrusions.
 5. The pallet of claim 1 wherein theouter surface of the second portion comprises at least two segments thatare closer to the first portion than the remainder of the secondportion.
 6. The pallet of claim 1 wherein the outer surface of thesecond portion comprises at least two feet.
 7. The pallet of claim 1wherein the outer surface of the second portion comprises a series ofridges and grooves.
 8. The pallet of claim 7 wherein the inner surfacesof the first and second portions each comprise a succession of curveshaving rises and falls that run perpendicular to the series of ridgesand grooves on the outer surface of the second portion and furthercomprising tine accepting channels in the second portion.
 9. The palletof claim 1 wherein the outer surface of the first portion is generallyplanar.
 10. The pallet of claim 1 wherein: a) the inner surface of thefirst portion is molded to the inner surface of the second portion; b)the pallet is formed from puncture-resistant plastics; and c) tack offpoints are located along peaks and valleys of the portions
 11. A palletcomprising: a pallet body including: a first portion having an outersurface and an inner surface having at least a portion of which that isdistant the outer surface and having a corrugating form; and a secondportion having an outer surface and an inner surface having at least aportion of which that is distant the outer surface and having acorrugating form, wherein the inner surface of the first portion isconnected to the inner surface of the second portion between eachrespective corrugating form.
 12. A pallet of claim 11 wherein the innersurface of the first portion is molded to the inner surface of thesecond portion.
 13. A method of forming a pallet comprising the stepsof: a) blow molding a first portion having an outer surface and an innersurface at least a portion of which is distant the outer surface; and b)blow molding a second portion having an outer surface and an innersurface at least a portion of which is distant the outer surface aroundthe first portion.
 14. A method of claim 13 wherein one of the firstportion and the second portion is inserted into a mold shaping the otherone of the first portion and the second portion prior to the blowmolding of the other one of the first portion and the second portion.15. A blow-molded pallet comprising: a) a bottom portion having a firstbottom surface and a first top surface wherein said top surface has afirst set of channels and protrusions; b) an upper portion having asecond top surface and a second bottom surface having a second set ofchannels and protrusions; and wherein the second set of channels andprotrusions of the upper portion interlock with the first set ofprotrusions and channels respectively of the bottom portion.
 16. Thepallet of claim 15, wherein the upper portion and the bottom portion arefused by applying heat to one of the portions and pressing the twoportions together.
 17. The pallet of claim 15, wherein at least oneportion contains cavities and wherein the other portion contains anextending member which is inserted into the cavity during molding tolock one portion to another portion.
 18. The pallet of claim 15, whereinone portion contains a locking member, and wherein the other portioncontains a receiving member so that the locking member and receivingmember communicate to lock one portion to the other portion.
 19. Thepallet of claim 15, wherein one portion has at least one tack off pointwhich allows the upper portion to become attached to the bottom portion.20. The pallet of claim 15, wherein the upper portion includes at leastone leg; and wherein the bottom portion includes one foot having ahollow portion for receiving a foot of the upper portion.
 21. The palletof claim 15, further comprising an upper portion first end and an upperportion second end included with the upper portion; and a bottom portionfirst end and a bottom portion second end included with the bottomportion, wherein at least the upper first end mates with the bottomfirst end.
 22. The pallet of claim 15, wherein the upper portion and thebottom portion are fused during molding.
 23. The pallet of claim 15,further comprising a) a lip extending from the pallet; b) radiusedcorners on edges of the pallet; and c) a third blow molded portion.